Centering blanks

ABSTRACT

A centering system comprising a conveyor for receiving a plurality of blanks outputted from a furnace and displacing the blanks along a first horizontal axis and shifting units for each individual blank including two or more adjustable lifting bars, the shifting units configured to move along a second horizontal axis, and the adjustable lifting bars being configured to lift the blanks along a vertical axis, wherein each of the shifting units is independently movable along the second axis, and a plurality of centering pins for centering the blanks, such that the blanks can be centered by moving the individual blanks along the second axis against the centering pins. Also disclosed are conveyor systems and methods for centering and conveying blanks.

This application claims priority to European Patent Application No.15382493.3, filed Oct. 13, 2015, the entire contents of which are herebyincorporated by reference.

The present disclosure relates to a centering system for centeringblanks outputted from a furnace and to conveying systems in hot formingproduction lines. The present disclosure further relates to methods forcentering and conveying blanks in a hot forming production line.

BACKGROUND

Several manufacturing industries produce and process metal blanks toobtain end products. In such processes, the blanks may be conveyed alonga production line. Some of these production lines comprise a hot formingprocess, e.g. a hot stamping process.

Hot stamping is a common process in e.g. the automotive industry whichallows manufacturing hot formed structural components with specificproperties which may include features such as a certain strength,thickness and lightness. In a hot stamping line system, a furnace systemthat heats and softens the blank to be hot formed is provided upstreamfrom a press system. The press system then deforms the blanksubstantially to the shape of the end product. After the press step,post operations such as calibrating, folding flanges, and drilling holesmay be performed. Typically in the automotive industry, high strengthsteel or ultra high strength steel blanks are used. The steel blanksobtain a suitable microstructure with high tensile strength by coolingthe blanks in the press or after the press. The increase in acomponent's strength obtained by these processes may allow for a thinnergauge material to be used, which results in weight savings overconventionally cold stamped mild steel components for automotiveapplications.

In order to increase productivity, the press systems may comprise aplurality of dies configured to stamp several blanks simultaneously. Asingle press system comprising a plurality of pairs of upper and lowerdies may be provided, in which each die pair (upper and lower die) isconfigured for stamping a blank. Or a plurality of press systems may beprovided, wherein each of the press systems comprises a single upper andlower die. Combinations hereof are also possible.

In this context, it is possible to consecutively and stably load blanksonto the workstations of the press machine by a blank loading system,and sequentially perform press work on the loaded blanks by one stroke,thereby improving productivity, and remarkably reducing the cost ofproduction. Alternatively, several parallel press systems can be used.

A conveyor system in such a production line is configured to convey acold blank to a furnace and through a furnace. A furnace and a conveyorsystem are configured such that the blanks are heated to a desiredtemperature and for a desired time period (e.g. 3-5 minutes) beforeexiting the furnace. The transportation of the components through thefurnace takes place on e.g. roller conveyors. In order to be able toform or press several blanks at the same time, several blanks areconveyed in parallel to each other and exit the furnace at the sametime.

As the blanks exit the furnace, the blanks need to be correctlypositioned in order to transfer the blanks correctly to the hot formingdies. If multiple blanks exit the furnace at the same time, the blanksneed to be correctly positioned with respect to each other so that theblanks may be transferred to the hot forming dies correctly. Thetransfer from the exit region of the furnace to the hot forming dies maybe done using industrial robots for each individual blank, or may bedone using a transportation fork that lifts all blanks at the same timeand deposits the blanks in the dies.

However, known methods of transferring heated blanks outputted from afurnace to a press tool comprising the above mentioned efficiencyimprovements and processing capacity are limited by the dimensions ofthe run-out section of the furnace versus the dimensions of the pressingtools.

The dies of the press system(s) require a certain positioning anddistance in between blanks in order for them to be simultaneously hotstamped. Such a restriction indirectly sets a limitation on the numberof blanks that can be fed by the furnace, as well as on which positionalong the conveyor they have to be fed.

The distances required between blanks in the dies mean that the samedistances have to be provided along the conveyor and in the furnace.Thus, the width of the furnace may need to be increased in some cases inorder to be able to press e.g. four or six blanks at the same time.

Additionally, the conveyors may become dirty along the parts of theconveyor(s) on which the blanks are placed. In order to avoid the blanksbecoming dirty, it would be desirable to place the blanks on differentportions of the conveyor(s).

The present disclosure seeks to provide improvements in centeringsystems configured to center blanks outputted from a furnace in a hotstamping line system and methods.

SUMMARY

In a first aspect, the present disclosure provides a centering systemfor centering blanks outputted from a furnace in a hot stamping line.The centering system comprises a conveyor for receiving a plurality ofblanks outputted from a furnace and displacing the blanks at least alonga first horizontal axis. The centering system further comprises shiftingunits for each individual blank comprising two or more adjustablelifting bars, the shifting units configured to move along a secondhorizontal axis substantially perpendicular to the first direction, andthe adjustable lifting bars being configured to lift the blanks along avertical axis substantially perpendicular to both the first and secondaxes. Herein each of the shifting units is independently movable alongthe second axis, and a plurality of centering pins for centering theblanks is provided, such that the blanks can be centered by moving theindividual blanks along the second axis against the centering pins.

At the exit of the furnace, each of the blanks may be positioned on anindividual shifting unit. The shifting units can lift the blanks up fromthe conveyor(s). Each of the shifting unit can be driven individuallyalong a direction perpendicular to the conveying direction at the exitof the furnace. Centering can take place by moving each of the blanksindividually against centering pins. By individually moving the blanks,the distance between individual blanks can be increased and adapted,which result comes from collaboration between shifting units andcentering pins. The distance between blanks can thus be increased inbetween the furnace and the press system(s). The same system alsoenables repositioning the blanks to the correct position if they areconveyed on different positions of the conveyor(s) if they have becomedirty.

Hereinafter, the direction of the conveying path is called the firstdirection or x-axis. The direction in the conveying plane which isperpendicular to the first direction is called the second direction ory-axis. The vertical direction which is perpendicular to the conveyingplane is called the third direction or z-axis.

It is noted however that the conveying path at the exit of the furnacemay be inclined in some implementations. The first direction (x-axis) isthen to be understood as the horizontal component of the conveyingdirection. The second direction or y-axis is horizontal as well andperpendicular to the x-axis. The third direction (z-axis) isperpendicular to both the x-axis and y-axis and is thus substantiallyvertical.

In a further aspect, a method for centering blanks in a hot forming lineis provided using such a centering system described. The methodcomprises receiving a plurality of blanks from a furnace and displacingthe plurality of blanks at least along a first horizontal axis, liftingthe blanks from a pre-centering plane defined by the first horizontalaxis and a second horizontal axis perpendicular to the first horizontalaxis, along a third axis perpendicular to the plane, and centering theblanks by individually moving the blanks along the second axis againstcentering pins.

In some examples, one or more of the centering pins are moveable alongthe y axis. This provides versatility to adapt the centering system toblanks of different shapes and dimensions without necessarily having toadapt the shifting units or shifting units movements. Additionally oralternatively, one or more of the centering pins are moveable along thevertical z-axis. The centering pins may be driven vertically in order toretract and provide an uninhibited passing of the blanks from thefurnace to a (pre)-centering plane. Once the blanks have reached thisplane, the centering planes may be driven so as to provide a blockingelement against which the blanks can be driven.

In some examples, the method may comprise pre-centering the blanks inthe pre-centering plane prior to lifting the blanks. As the blanks areconveyed through the furnace they may be moved slightly and it ispossible that the blanks do not exit the furnace in a straightorientation. The pre-centering may be performed by centering pins movingin the second direction. In some examples, dedicated “pre-centeringpins” may be provided. Pre-centering pins as used herein are to beunderstood as pins exclusively used for pre-centering. Pins exclusivelyused or also used for centering are herein regarded as centering pins.In other examples, pre-centering may be carried out by the same pinsthat ensure centering.

In some examples, the centering system may comprise four shifting units,i.e. for four blanks. In some of these examples, pairs of the shiftingunits are configured for moving from a neutral position to a centeringposition in opposite directions. The distance between the pairs ofblanks may thus be increased. The distance between individual blanks ofthe pairs may be adjusted by the centering pins.

In a further aspect, a conveyor system is provided including a centeringsystem and a transfer robot for each individual blank to transfer theblanks individually to a hot forming press.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting examples of the present disclosure will be described in thefollowing, with reference to the appended drawings, in which:

FIG. 1 schematically shows in a top view an example of a centeringsystem for centering blanks outputted from a furnace in a hot stampingline;

FIG. 2 schematically illustrates a cross-sectional side view of anexample of a centering system for centering blanks; and

FIGS. 3a-3e schematically illustrate in a top view a sequence ofsituations occurring during the performance of an example of a methodfor centering blanks.

DETAILED DESCRIPTION OF EXAMPLES

FIG. 1 schematically represents a centering system 1 for centeringblanks outputted from a furnace 15 in a hot stamping line according toan example. Blanks may be transported by a conveyor system. In thisexample, a roller conveyor comprising a large number of conveyor rollersis shown. The conveyor rollers are distanced from each other in aconveying direction (x-axis in FIG. 1). The rollers may be driven bymotors that can control the speed of the conveyor rollers.

Conveyor rollers 14 convey the blanks through furnace 15. In thefurnace, the blanks are heated to a desired temperature. For example, incase boron steel blanks are used, a desired temperature may be around900° C. At the exit of the furnace, a door 12 is provided. The door isconfigured or controlled to open when the blanks arrive and to closeagain when the blanks have left the furnace. This way the heat producedinside the furnace can be kept inside the furnace.

As the blanks leave the furnace 15, they are conveyed through furtherrollers 16 towards stoppers 22. In the specific example shown, the hotforming line is designed for four blanks being hot formedsimultaneously. Thus four blanks may be conveyed side by side throughthe furnace and onto the centering table. Each of the stoppers 22 may beindividually controllable and move in the conveying direction (along thex-axis). The position of the stoppers determines the end position of theblanks before centering takes place. The conveyor rollers 16 may beintermittently driven. As the blanks exit the furnace, these conveyorrollers 16 are rotated to convey the blanks until they reach thestoppers. Then the rollers may be stopped.

In this particular example, the centering table 1 may be composed byfour independent shifting units 20 having eight lifting bars 18. Each ofthe lifting bars is arranged in between two of the conveyor rollers 16.The lifting bars can thus move upwards (in the illustration of FIG. 1,upward out of the paper; z-axis as indicated in FIG. 2) in between theconveyor rollers to lift the blanks out of the “pre-centering plane”.

The system may also comprise a plurality of centering pins 24 andpre-centering pins. A selection of the centering pins may benon-actuated pins and others may be actuated pins, which meansrespectively that they are either retracted with respect to the movementpath of the blanks, and therefore they are not interacting with theblanks, or that they are non-retracted with respect to the movement pathof the blanks, and therefore they are able to interact with the edges ofthe blanks (i.e. stop and/or center the blanks). The selection of pinsthat are actuated and non-actuated may be adapted in accordance with thenumber of blanks, type of blanks and dimensions of blanks.

A selection of the pins may be passive, i.e. they always maintain thesame position, and the same height. A selection or all of the pins maybe controlled to adapt their height. For example, the pins may beunderneath the plane of the conveying plane (i.e. the plane coincidingwith the top of the conveyor rollers) as the blanks are conveyed towardsthe stoppers. Then, subsequently for centering the pins may be raised toreach a height at least above the conveying plane. Similarly, aselection of the pins may be controlled to adapt their position in ahorizontal direction perpendicular to the conveying direction, i.e.along the y-axis indicated in FIG. 1.

In some examples, pre-centering may occur after the blanks have reachedthe stoppers. The position of the blanks along the x-axis is therebydetermined. Then, in order to bring the blanks in the correctorientation, a number of (pre)-centering pins may be driven along they-axis and slightly reposition of the blanks.

After the optional pre-centering step, the lifting bars 18 of eachshifting unit 20 can move along the z-axis and raise the blanks. Then,the shifting units may be displaced along the y-axis against centeringpins. The centering pins thereby determine the end positions of theblanks.

It may be seen that the width of the centering table 1 is larger thanthe width of the furnace 15. In an example, the furnace may have a widthof approximately 2.3 meters, whereas the width of the centering table 1may be approximately 3 meters. The centering table according to thisexample makes it possible to increase the distance between the blanks inorder for their further processing. The width of the furnace does notneed to be increased accordingly, which can reduce the cost of thefurnace as well as the energy consumption.

FIG. 2 schematically illustrates a cross-sectional side view of acentering system for centering blanks according to the example ofFIG. 1. In FIG. 2, the shifting units 20 and the lifting bars 18 are ina retracted position, below the conveying plane defined by the topsurface of the conveyor rollers 16. Moreover, pins 24 are as wellretracted and thus, below the rollers 16 level.

In FIG. 2, four separate shifting units 20 a, 20 b, 20 c and 20 d areshown. Each of these shifting units may comprise base 23 and an actuator27 to adapt the height of the lifting bars 18. The base 23 a andactuator 27 a are indicated for shifting unit 20 a. The actuator shownmay be e.g. a hydraulic or pneumatic or actuator. In some examples, eachof the lifting bars may have an individual actuator.

Also shown in FIG. 2 are a plurality of pin bases 26 a, 26 b, 26 c and26 d in which pins 24 are sunk (in the situation shown in FIG. 2). Thepins may be driven out of their bases using suitable actuators (e.g.hydraulic, pneumatic or electric involving gears).

The pin bases may be elongated guides along which the pins can slide. Inthe view of FIG. 1, they may extend sideways and may be arranged inbetween the conveyor rollers. The bases and the lifting bars may berelatively thin so that they fit next to each other in between theconveyor rollers 16.

FIGS. 3a-3e schematically illustrate in top view a sequence ofsituations occurring during an example of a method for centering blanks.The centering system depicted in the sequence of FIGS. 3a-3e isgenerally very similar to the system of FIGS. 1 and 2. The same elementsare indicated using the same reference signs.

In this case, active centering pins are indicated with reference signs24. Passive centering pins (at least in the shown sequence) areindicated with reference signs 25. As mentioned earlier, in a sequenceinvolving different blanks of different shape or different dimensions,some of the pins which are herein shown to be active may then be passiveand vice versa.

In FIG. 3a , four blanks are shown. A pair of blanks 10 a and 10 b is ofa first type, whereas another pair of blanks 11 a and 11 b is of adifferent type. The blanks are shown to be in the furnace, whereas thedoor 12 of the furnace is closed. The conveyor rollers 14 are driven toconvey the blank towards the exit and towards the centering table.

In FIG. 3b , the furnace door 12 has been opened (and is therefore notshown in this figure) and the stoppers 22 a-22 d have been moved totheir stopping position. Stoppers 22 a and 22 b are in a stoppingposition to determine the end position in the x-direction of blanks 10 aand 10 b. Since blanks 11 a and 11 b have a different size, the positionof stoppers 22 c and 22 d in the x-direction may be different inaccordance with what is shown in FIG. 2 b.

As the blanks exit the furnace, conveyor rollers 16 are driven toforward the blanks in the x-direction (FIG. 3c ). When the blanks touchtheir respective stoppers, the conveyor rollers may be inactivated, sothat when the stoppers 22 a-22 d return to their original position, theblanks do not move.

At this stage, a pre-centering step may take place (not illustrated). Anumber of pre-centering pins may be moved along the y-direction tocorrectly orient the blanks.

In FIG. 3d , the furnace door 12 is shown to be closed again and thestoppers 22 a-22 d have moved partly towards their original position.The blanks may then be lifted out of the conveying plane using thelifting bars 18 that are raised along the z-axis. Substantially at thesame time, centering pins 24 are raised in the same direction. Some ofthe centering pins may have already been in a raised position. Forexample, centering pins 24 a, 24 b, 24 g and 24 h are relatively farremoved from a normal conveying path of the blanks and there would be noneed to withdraw them underneath the conveying plane.

On the contrary, centering pins 24 d, 24 e and 24 f (and also centeringpin 24 c, only shown in FIG. 3e ) may interfere with the movement of theblanks. These centering pins may thus be raised to their position forcentering after the blanks have reached their respective stoppers.

Then the shifting units 22 a and 22 b with their corresponding liftingbars may be moved towards the left (in a “negative” direction along they-axis), whereas the shifting units 22 c and 22 d may be moved towardsthe right (in a “positive” direction along the y-axis). In the case ofcentering pin 24 c, this pin may be raised to its position used forcentering only after the shifting units have started moving.

In the situation of FIG. 3e , the blanks touch the respective centeringpins. When blanks touch centering pins, they are still in place even ifthe shifting unit is moved a little bit further. Thus the centering pindetermines the position along the y-axis. Blank 10 a is in contact withcentering pins 24 a and 24 b. Blank 10 b is in contact with centeringpins 24 c and 24 d. Blank 11 a is in contact with centering pins 24 eand 24 f. Blank 11 b is in contact with centering pins 24 g and 24 h.

The shifting units 20 a and 20 b, as compared to previous figures havebeen moved along the y-axis in a negative direction. The shifting units20 c and 20 d have moved along the y-axis in a position direction.

As illustrated in FIG. 3e , the outer shifting units 20 a and 20 d mayhave moved more than the inner shifting units 20 b and 20 c. Theshifting units will thus not interfere with each other. Distance y2 islarger than distance y1. Similarly, distance y4 may be larger thandistance y3, or at least of substantially the same magnitude.

By moving the shifting units in opposite directions, the distancebetween the pairs of blanks has been increased. Similarly, by themovements of the shifting units and the positions of the centering pins,the distance between blanks 10 a and 10 b and the distance betweenblanks 11 a and 11 b may be increased. The outer positions of the blanksmay thus be beyond the width of the furnace. The furnace may thus benarrower, whereas at the same time the blanks may have sufficientspacing in order to be able to be transferred to the hot press(es)correctly.

Similarly, if portions of the conveyors have become dirty, the blanksmay be positioned slightly differently on the conveyors so as to avoidthe blanks becoming dirty. The centering table as proposed hereinensures that each of the blanks may still be positioned in the same endposition even if they exit the furnace in slightly different positionsalong the y-axis.

A transfer robot (not shown), for example a suitable industrial robot,may pick up a blank from the shifting unit and place it on the hot press(not shown). The transfer robot to this end may comprise a plurality ofgripping units to grab and pick up the blanks.

Gripping unit as used herein is to be understood as covering e.g.suction cups, clamps or similar.

In some examples, a single transfer robot may comprise several groups ofgripping units, each group configured for picking up a blank, i.e. asingle transfer robot can pick up more than one blanks at the same time.

In other examples, a plurality of transfer robots is provided, whereineach of the transfer robots is configured to pick up a single blank.

The expression “industrial robot” herein e.g. covers an automaticallycontrolled, reprogrammable, and optionally multipurpose, manipulatorprogrammable in three or more axes, which may be either fixed in placeor mobile for use in industrial automation applications, as defined bythe International Organization for Standardization in ISO 8373.

Even though the transfer robots may be (re) programmable, in accordancewith their programming they will be able to pick up blanks only if theyare positioned and centered correctly and consistently. This is what thecentering table according to the examples and according to the methodsdisclosed herein ensures.

Although only a number of examples have been disclosed herein, otheralternatives, modifications, uses and/or equivalents thereof arepossible. In particular, the examples shown herein are adapted forpressing and conveying four blanks at the same time. In other examples,e.g. two or three or six blanks may be pressed at the same time andconveyed side-by-side. In these examples, each of the blanks may have anindividual shifting unit and optionally an individual transfer robot fortransferring the blanks from the centering table towards the hotpress(es).

Furthermore, all possible combinations of the described examples arealso covered. Thus, the scope of the present disclosure should not belimited by particular examples, but should be determined only by a fairreading of the claims that follow.

1.-17. (canceled)
 18. A method for centering blanks in a hot formingline, the method comprising: receiving a first and a second blanksimultaneously from a furnace and displacing the first and second blanksat least along a first horizontal axis with a conveyor; lifting thefirst and second blanks vertically from a pre-centering plane defined bythe first horizontal axis and a second horizontal axis perpendicular tothe first horizontal axis, wherein the lifting comprises lifting thefirst blank with a first shifting unit and lifting the second blank witha second shifting unit; centering the blanks by moving the first blankwith the first shifting unit along the second axis against centeringpins, and moving the second blank with the second shifting unit againstcentering pins.
 19. The method according to claim 18, further comprisingpre-centering the blanks in the pre-centering plane prior to lifting theblanks.
 20. The method according to claim 18, wherein centering theblanks comprises moving the first blank in a first direction along thesecond axis, and moving the second blank in a second direction along thesecond axis, wherein the second direction is opposite to the firstdirection.
 21. The method according to claim 18, wherein centering theblanks comprises moving the first blank and the second blank in the samedirection along the second axis.
 22. The method according to claim 21,wherein centering the blanks comprises separating the first and thesecond blank.
 23. The method according to claim 18, wherein centeringthe blanks comprises moving one or more of the centering pins to acentering position prior to moving the first and second blanks againstthe centering pins.
 24. The method according to claim 23, wherein someof the centering pins have a different height than some others of thecentering pins.
 25. The method of claim 18, wherein the first and secondshifting units are independently movable along the second axis.
 26. Themethod of claim 18, wherein the first and second shifting units comprisetwo or more adjustable lifting bars.
 27. A method according to claim 26,wherein the conveyor is a rolling conveyor having a plurality ofconveyor rollers separated along the first axis, wherein the liftingbars of the shifting units are arranged in between the conveyor rollers.28. The method of claim 18, wherein the conveyor displaces the first andsecond blanks along the first horizontal axis against one or morestoppers.
 29. The method of claim 18, wherein one or more of thecentering pins are moveable vertically.
 30. The method of claim 18,further comprising transferring the first and second blanks to a hotforming press using a first and second transfer robot.
 31. A methodcomprising: receiving a first and a second blank simultaneously from afurnace and displacing the first and second blanks at least along afirst horizontal axis with a conveyor; lifting the first and secondblanks vertically from a pre-centering plane defined by the firsthorizontal axis and a second horizontal axis perpendicular to the firsthorizontal axis; individually moving the first and second blanks alongthe second horizontal axis against centering pins; and transferring thefirst and second blanks to a hot forming press.
 32. The method of claim31, wherein individually moving the first and second blanks comprisesmoving the first blank in a first direction along the second axis, andmoving the second blank in a second direction along the second axis,wherein the second direction is opposite to the first direction.
 33. Themethod according to claim 31, wherein the conveyor is a rolling conveyorhaving a plurality of conveyor rollers separated along the firsthorizontal axis.
 34. The method according to claim 33, wherein thelifting the first and second blanks comprises lifting the first andsecond blanks with shifting units comprising two or more lifting bars,wherein the lifting bars are vertically moveable, and wherein thelifting bars are arranged between the conveyor rollers.
 35. The methodaccording to claim 31, wherein the first and the second blanks arereceived simultaneously from the furnace with a separation along thesecond horizontal axis between the first and second blanks, and whereinindividually moving the first and second blanks along the secondhorizontal axis comprises increasing the separation between the firstand second blanks.
 36. The method according to claim 31, furthercomprising pre-centering the first and second blanks in thepre-centering plane prior to lifting the first and second blanks. 37.The method according to claim 36, further comprising vertically movingone or more of the centering pins prior to individually moving the firstand second blanks along the second horizontal axis against the centeringpins.